JP2018175483A - シートクッション材の製造方法及びその製造用発泡型 - Google Patents
シートクッション材の製造方法及びその製造用発泡型 Download PDFInfo
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- 239000000463 material Substances 0.000 title claims abstract description 69
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 39
- 238000005187 foaming Methods 0.000 title claims abstract description 13
- 239000002344 surface layer Substances 0.000 claims abstract description 73
- 239000002994 raw material Substances 0.000 claims abstract description 29
- 238000000034 method Methods 0.000 claims abstract description 15
- 238000000465 moulding Methods 0.000 claims abstract description 14
- 238000002360 preparation method Methods 0.000 claims abstract description 3
- 239000010410 layer Substances 0.000 claims description 98
- 239000006260 foam Substances 0.000 claims description 28
- 229920005989 resin Polymers 0.000 claims description 22
- 239000011347 resin Substances 0.000 claims description 22
- 230000000149 penetrating effect Effects 0.000 claims description 9
- 229920002803 thermoplastic polyurethane Polymers 0.000 abstract description 12
- 238000003825 pressing Methods 0.000 abstract description 3
- 238000010097 foam moulding Methods 0.000 description 11
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 description 9
- 210000000689 upper leg Anatomy 0.000 description 9
- 210000001217 buttock Anatomy 0.000 description 8
- 239000011324 bead Substances 0.000 description 7
- 229920005749 polyurethane resin Polymers 0.000 description 6
- 230000007547 defect Effects 0.000 description 5
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 4
- 230000000694 effects Effects 0.000 description 4
- 230000002411 adverse Effects 0.000 description 3
- 230000007423 decrease Effects 0.000 description 3
- 229920005672 polyolefin resin Polymers 0.000 description 3
- PPBRXRYQALVLMV-UHFFFAOYSA-N Styrene Chemical compound C=CC1=CC=CC=C1 PPBRXRYQALVLMV-UHFFFAOYSA-N 0.000 description 2
- 229910052742 iron Inorganic materials 0.000 description 2
- -1 polypropylene Polymers 0.000 description 2
- NLHHRLWOUZZQLW-UHFFFAOYSA-N Acrylonitrile Chemical compound C=CC#N NLHHRLWOUZZQLW-UHFFFAOYSA-N 0.000 description 1
- 239000004698 Polyethylene Substances 0.000 description 1
- 239000004743 Polypropylene Substances 0.000 description 1
- 238000007792 addition Methods 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 229920001577 copolymer Polymers 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 238000012217 deletion Methods 0.000 description 1
- 230000037430 deletion Effects 0.000 description 1
- 239000004088 foaming agent Substances 0.000 description 1
- 210000002414 leg Anatomy 0.000 description 1
- 239000008188 pellet Substances 0.000 description 1
- 230000002093 peripheral effect Effects 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
- 229920001155 polypropylene Polymers 0.000 description 1
- 238000003466 welding Methods 0.000 description 1
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- B60N2/00—Seats specially adapted for vehicles; Arrangement or mounting of seats in vehicles
- B60N2/02—Seats specially adapted for vehicles; Arrangement or mounting of seats in vehicles the seat or part thereof being movable, e.g. adjustable
- B60N2/0284—Adjustable seat-cushion length
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
- B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
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- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C5/00—Chairs of special materials
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- A47C5/125—Chairs of special materials of plastics, with or without reinforcement completely made of foam material
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- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C7/00—Parts, details, or accessories of chairs or stools
- A47C7/02—Seat parts
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- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
- B29C43/18—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles
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- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
- B29C44/04—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles consisting of at least two parts of chemically or physically different materials, e.g. having different densities
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
- B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/34—Auxiliary operations
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
- B32B5/32—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed at least two layers being foamed and next to each other
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60N—SEATS SPECIALLY ADAPTED FOR VEHICLES; VEHICLE PASSENGER ACCOMMODATION NOT OTHERWISE PROVIDED FOR
- B60N2/00—Seats specially adapted for vehicles; Arrangement or mounting of seats in vehicles
- B60N2/24—Seats specially adapted for vehicles; Arrangement or mounting of seats in vehicles for particular purposes or particular vehicles
- B60N2/32—Seats specially adapted for vehicles; Arrangement or mounting of seats in vehicles for particular purposes or particular vehicles convertible for other use
- B60N2/36—Seats specially adapted for vehicles; Arrangement or mounting of seats in vehicles for particular purposes or particular vehicles convertible for other use into a loading platform
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60N—SEATS SPECIALLY ADAPTED FOR VEHICLES; VEHICLE PASSENGER ACCOMMODATION NOT OTHERWISE PROVIDED FOR
- B60N2/00—Seats specially adapted for vehicles; Arrangement or mounting of seats in vehicles
- B60N2/62—Thigh-rests
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60N—SEATS SPECIALLY ADAPTED FOR VEHICLES; VEHICLE PASSENGER ACCOMMODATION NOT OTHERWISE PROVIDED FOR
- B60N2/00—Seats specially adapted for vehicles; Arrangement or mounting of seats in vehicles
- B60N2/70—Upholstery springs ; Upholstery
- B60N2/7017—Upholstery springs ; Upholstery characterised by the manufacturing process; manufacturing upholstery or upholstery springs not otherwise provided for
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
- B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
- B29C44/1271—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements the preformed parts being partially covered
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
- B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
- B29C44/14—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements the preformed part being a lining
- B29C44/148—Applying the foaming resin, moulding the lining or the like, with the lining turned inside out
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/34—Auxiliary operations
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2075/00—Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29K2105/24—Condition, form or state of moulded material or of the material to be shaped crosslinked or vulcanised
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29K2623/00—Use of polyalkenes or derivatives thereof for preformed parts, e.g. for inserts
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Aviation & Aerospace Engineering (AREA)
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- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
- Mattresses And Other Support Structures For Chairs And Beds (AREA)
Abstract
Description
10 表層パッド(表層部)
11 表面部
11a 縦溝(溝)
11a1 後孔部
11a2 前孔部
20 裏層パッド(裏層部)
21 表側部
22 裏側部
40 ウレタン発泡成形型(製造用発泡型)
41 下型
41a 下キャビティ面
41b 後突起部(突起部)
41b1 上底部(先端部)
41b2 下底部(連結部)
41b3 貫通孔
41c 前突起部(突起部)
41c3 貫通孔
41b31 くびれ部
42 上型
42a 上キャビティ面
43 キャビティ
M 発泡ウレタン樹脂原料(発泡樹脂材料)
Claims (8)
- 着座面側に配置される表層部と、該表層部の着座面と反対側に配置され該表層部より硬くかつ密度が小さい裏層部とを、一体化した層状構造を有するシートクッション材の製造方法であって、
前記裏層部は前記シートクッション材の着座面と反対側の形状の少なくとも一部を構成する裏側面を有し、
前記シートクッション材の着座面と反対側の形状に対応する上キャビティ面を有する上型に前記裏層部を、前記裏側面を前記上キャビティ面に当接させて取付ける準備工程と、
前記シートクッション材の着座面側の形状に対応する下キャビティ面を有する下型であって、該下キャビティ面には前記下型に対して前記裏層部の取付けられた状態の前記上型が閉じられたとき前記裏層部の着座面側に当接して前記裏層部を上キャビティ面に対して押し付ける複数の突起部が設けられている下型の前記下キャビティ面上に前記表層部を形成する発泡樹脂原料を投入して前記裏層部の取付けられた状態の前記上型を閉じ前記表層部を成形して前記裏層部と一体化する成形工程と、
該成形工程で成形された前記シートクッション材を脱型する脱型工程と、を備えるシートクッション材の製造方法。 - 請求項1に記載のシートクッション材の製造方法であって、前記突起部は前記表層部の着座面側に設けられた着座面と反対側方向に凹む溝の位置に対応して該溝の幅と略同一な板状部材として形成されているシートクッション材の製造方法。
- 請求項2に記載のシートクッション材の製造方法であって、前記突起部は前記下キャビティ面に連結された連結部から前記裏層部に当接する先端部にかけて着座面と平行な面で切ったときの断面の外形面積が徐々に減少するように形成されており、該連結部の近傍には板厚方向に貫通する貫通孔が設けられているシートクッション材の製造方法。
- 請求項3に記載のシートクッション材の製造方法であって、前記貫通孔を着座面と平行な面で切ったときの断面が前記突起部の板厚方向の略中央部において最もくびれた形状に形成されているシートクッション材の製造方法。
- 着座面側に配置される表層部と、該表層部の着座面と反対側に配置され該表層部より硬くかつ密度が小さい裏層部とを、一体化した層状構造を有するシートクッション材の製造用発泡型であって、
前記シートクッション材の着座面と反対側の形状の少なくとも一部を構成する裏側面を有する前記裏層部を、前記裏側面を当接させて取付けることができる前記シートクッション材の着座面と反対側の形状に対応する上キャビティ面を有する上型と、
前記シートクッション材の着座面側の形状に対応する下キャビティ面を有する下型であって、該下キャビティ面には前記下型に対して前記裏層部の取付けられた状態の前記上型が閉じられたとき前記裏層部の着座面側に当接して前記裏層部を上キャビティ面に対して押し付ける複数の突起部が設けられている下型と、を有し、
前記下キャビティ面上に前記表層部を形成する発泡樹脂原料を投入して前記裏層部の取付けられた状態の前記上型を閉じ前記表層部を成形して前記裏層部と一体化するシートクッション材の製造用発泡型。 - 請求項5に記載のシートクッション材の製造用発泡型であって、前記突起部は前記表層部の着座面側に設けられた着座面と反対側方向に凹む溝の位置に対応して該溝の幅と略同一な板状部材として形成されているシートクッション材の製造用発泡型。
- 請求項6に記載のシートクッション材の製造用発泡型であって、前記突起部は前記下キャビティ面に連結された連結部から前記裏層部に当接する先端部にかけて着座面と平行な面で切ったときの断面の外形面積が徐々に減少するように形成されており、該連結部の近傍には板厚方向に貫通する貫通孔が設けられているシートクッション材の製造用発泡型。
- 請求項7に記載のシートクッション材の製造用発泡型であって、前記貫通孔を着座面と平行な面で切ったときの断面が前記突起部の板厚方向の略中央部において最もくびれた形状に形成されているシートクッション材の製造用発泡型。
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